U.S. patent application number 10/563348 was filed with the patent office on 2008-05-08 for components for static micromixers, micromixers constructed from such components and use of such micromixers for mixing or dispersing or for carrying out chemical reactions.
This patent application is currently assigned to WELLA AG. Invention is credited to Gerhard Schanz, Gerhard Sendelbach.
Application Number | 20080106968 10/563348 |
Document ID | / |
Family ID | 34088828 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080106968 |
Kind Code |
A1 |
Schanz; Gerhard ; et
al. |
May 8, 2008 |
Components for Static Micromixers, Micromixers Constructed from
such Components and Use of such Micromixers for Mixing or
Dispersing or for Carrying Out Chemical Reactions
Abstract
Components for static micromixers, micromixers constructed from
such components and processes carried out by the use of said
micromixers are described. The components are in the form of a disk
with at least one inlet opening (2) for introducing at least one
feed stream into a linking channel (3) disposed in the plane of the
disk and at least one outlet opening (4) for the outflow of the
feed stream into a mixing zone (5), wherein the inlet opening (2)
is connected in a communicating manner with the outlet opening (4)
through the linking channel (3) disposed in the plane of the disk
and wherein the linking channel (3) before opening into the mixing
zone (5) is divided by microstructure units (6) into two or more
part channels, the widths of the part channels being in the
millimeter to submillimeter range and being smaller than the width
of the mixing zone (5). The micromixers can be used for mixing,
homogenizing, dispersing, emulsifying, dissolving or gassing
liquids or for carrying out chemical reactions and particularly
combustion reactions.
Inventors: |
Schanz; Gerhard; (Darmstadt,
DE) ; Sendelbach; Gerhard; (Darmstadt, DE) |
Correspondence
Address: |
MICHAEL J. STRIKER
103 EAST NECK ROAD
HUNTINGTON
NY
11743
US
|
Assignee: |
WELLA AG
Darmstadt
DE
|
Family ID: |
34088828 |
Appl. No.: |
10/563348 |
Filed: |
June 4, 2004 |
PCT Filed: |
June 4, 2004 |
PCT NO: |
PCT/EP04/06042 |
371 Date: |
September 19, 2007 |
Current U.S.
Class: |
366/134 |
Current CPC
Class: |
B01F 15/00935 20130101;
B01F 5/0475 20130101; B01J 19/0093 20130101; B01J 2219/00783
20130101; B01J 2219/0086 20130101; B01F 13/0066 20130101; B01J
2219/00889 20130101; B01F 2215/0431 20130101; B01F 13/0094
20130101; B01F 13/0064 20130101 |
Class at
Publication: |
366/134 |
International
Class: |
B01F 15/02 20060101
B01F015/02 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 25, 2003 |
DE |
103 33 922.1 |
Claims
1. Component for a static micromixer in the form of a disk (1)
which has at least one inlet opening (2) for the introduction of at
least one feed stream into a linking channel (3) disposed in the
plane of the disk and at least one outlet opening (4) for the
outflow of the feed stream into a mixing zone (5) disposed in the
plane of the disk, wherein the inlet opening (2) is connected with
the outlet opening (4) in a communicating manner through the
linking channel (3) disposed in the plane of the disk, and wherein
the linking channel (3) before opening into the mixing zone (5) is
divided by microstructure units (6) into two or more part channels
(7), the widths of the part channels being in the millimeter to
submillimeter range and being smaller than the width of the mixing
zone (5).
2. Component as defined in claim 1, characterized in that the
widths of the part channels (7) at their opening into the mixing
zone are from 1 .mu.m to 2 mm.
3. Component as defined in claim 1, characterized in that the ratio
of the greatest width of the linking channel (3) and/or of the
width of the inlet opening (2) to the width of the part channels
(7) is greater than 2.
4. Component as defined in claim 1, characterized in that the ratio
of the length to the width of the part channels (7) is from 1:1 to
20:1.
5. Component as defined in claim 1, characterized in that the ratio
of the width of the mixing zone (5) to the width of the part
channels (7) is greater than 2.
6. Component as defined in claim 1, characterized in that
additionally it has at least one flow-through opening (9).
7. Component as defined in claim 1, characterized in that at least
one of the inlet openings (2) or flow-through openings (9) or the
mixing zone (5) is enclosed by the plane of the disk and that the
linking channel (3) is formed by an indentation.
8. Component as defined in claim 1, characterized in that at least
one of the inlet openings (2) or flow-through openings (9) or the
mixing zone (5) is disposed at the edge of the disk or as a recess
at the edge of the disk.
9. Component as defined in claim 1, characterized in that there are
present at least two inlet openings (2) for at least two different
feed streams, each inlet opening (2) being connected with the
mixing zone (5) through the linking channel (3).
10. Component as defined in claim 9, characterized in that there
are present two inlet openings (2) for two different feed streams,
each inlet opening (2) being connected with the mixing zone (5)
through one linking channel (3) and the outlet openings (4) of the
two linking channels (3) being disposed opposite one another.
11. Component as defined in claim 1, characterized in that the
outlet openings (4) are arranged on a circular line.
12. Component as defined in claim 1, characterized in that it has
additional through-holes (12) and additional part channels (13) the
latter being integrated into the microstructure units (6) and being
separated from the part channels (7).
13. Static micromixer which has a housing (11) with at least 2
fluid inlets (12a) and at least one fluid outlet (16) and at least
two disks as defined in claim 1 arranged into a stack in the
housing (11), wherein the disks (1) are superposed on one another
so that the inlet openings (2) form subsidiary channels for
introducing a particular feed stream and the mixing zones (5) form
a main channel for removing the product stream, and the main and
subsidiary channels extend through the stack.
14. Micromixer as defined in claim 13, characterized in that the
linking channels (3) of the disks (1) are formed by indentations
and that the linking channels (3), before opening into the mixing
zone (5), are divided into part channels (7) by the microstructure
units (6) provided on the disks.
15. Micromixer as defined in claim 13, characterized in that the
linking channels (3) of the disks (1) are formed by recesses in the
disks (1), the disks (1) being arranged as intermediate disks
between a cover disk and a bottom disk, and that the linking
channels (3) before opening into the mixing zone (5) are divided
into part channels (7) by microstructure units (6) provided on the
cover disks and/or bottom disks.
16. Micromixer as defined in claim 13, characterized in that it has
an integrated heat exchanger.
17. Combustion reactor having a micromixer with at least one
component as defined in claim 1, at least one first connection for
introducing a combustible liquid or gaseous medium, and at least
one second connection for introducing a combustion
reaction-promoting medium.
18. Mixing process whereby at least two fluid feed streams, at
first kept separated, are mixed with each other, characterized in
that the mixing is carried out by use of at least one component as
defined in claim 1.
19. Process as defined in claim 18, characterized in that the flow
rate at which the feed stream is fed to the mixing zone is greater
than the flow rate of the product stream within the mixing
zone.
20. Process for producing dispersions or solutions whereby a
continuous liquid phase is mixed with at least one insoluble fluid
phase that is to be dispersed or with at least one soluble fluid
phase, characterized in that the mixing is carried out by use of a
component as defined in claim 1.
21. Process as defined in claim 20, characterized in that the
continuous phase is conveyed through the main channel and the phase
to be dispersed or dissolved is conveyed through at least one
subsidiary channel of a micromixer.
22. Process for carrying out chemical reactions whereby at least
two fluid feed streams, at first kept separated, and which contain
or consist of reactive constituents are mixed with one another and
whereby during or after the mixing a chemical reaction takes place
among the constituents spontaneously or induced by a supply of
energy or by a suitable catalyst, characterized in that the mixing
is carried out by use of at least one component as defined in claim
1.
23. Use of microcomponents as defined in claim 1 for mixing,
homogenizing, dispersing, emulsifying, dissolving or gassing
liquids or for carrying out chemical reactions.
Description
[0001] The object of the invention are disk-shaped components for
static micromixers, micromixers constructed from such disks, mixing
and dispersing processes as well as processes for carrying out
chemical reactions by use of such micromixers.
[0002] The objective of mixing at least two fluids is to attain a
uniform distribution of the two fluids within a certain, as a rule
short, time. In dynamic mixers, the mixing takes place by use of
mechanically actuated agitators which cause turbulent flow
conditions. Dynamic mixers have the drawback that because of the
required mechanical components they cannot be readily reduced in
size. In static mixers, the mixing takes place without the use of
movable parts. These mixers can be reduced in size to give
so-called static micromixers of which various embodiments are
known. Static micromixers have the advantage that the size of the
components can be reduced and that therefore they can be integrated
into other systems such as heat exchangers and reactors. By
cooperation between two or more components interconnected in a
narrow space, additional possibilities exist in terms of process
optimization. The very narrow distribution of mixing times
achievable in static micromixers offers many possibilities of
optimization of chemical reactions in terms of selectivity and
yield. It is possible to achieve mixing times between 1 second and
a few milliseconds, the mixing of gases taking place even much
faster. The application potential of micromixers ranges from
liquid-liquid and gas-gas mixing to the formation of liquid-liquid
emulsions, gas-liquid dispersions and thus also to multiphase
reactions and phase-transfer reactions.
[0003] One class of micromixers is based on diffusion-controlled
mixing processes. To this end, alternately adjacent fluid lamellae
with a thickness in the micrometer range are formed. By an
appropriate selection of the geometry, it is possible to adjust the
width of the fluid lamellae and thus the diffusion paths. Such
static micromixers are described, for example, in DE 199 27 556 A1,
DE 202 06 371 U1 and WO 02/089962. The drawback of micromixers
based on diffusion between microscopic fluid lamellae is that a
relatively low flow velocity is needed for creating and maintaining
laminar flow conditions. This mixing principle allows only
relatively low throughputs.
[0004] Also known are micromixers consisting of guide components
provided with passing-through channels or of films provided with
grooves which when superposed on one another form a number of
channels for the different fluids that are to be mixed, the
dimensions of the channels being in the micrometer range. The feed
streams emerge from the channels into a mixing space as adjacent
fluid lamellae, the mixing taking place by diffusion and/or as a
result of turbulence (see, in particular, WO 97/17139 and the
literature cited therein as well as WO 97/17133, WO 95/30475, WO
97/16239 and WO 00/78438). The fabrication of these components is
relatively expensive and complicated, and as a result of the fluids
to be mixed having to pass through a multiplicity of long and very
narrow channels, the pressure losses are relatively high. If high
throughputs are to be achieved, the use of powerful pumping systems
may be required.
[0005] The object of the invention is to provide a process and a
device for mixing at least two fluids which at low pressure losses
permit fast and intensive mixing by use of the required components
which occupy a small space and are simple to fabricate.
[0006] In the following, by the term "fluid" is meant a gaseous or
liquid substance or a mixture of such substances that can contain
one or more solid, liquid or gaseous dissolved or dispersed
substances. The term "mixing" also includes the processes of
dissolving, dispersing and emulsifying. Hence, the term "mixture"
comprises solutions, liquid-liquid emulsions and gas-liquid and
solid-liquid dispersions.
[0007] The above-indicated objective is reached by way of static
micromixers that are provided with the components of the invention.
A component of the invention has the shape of a disk which
[0008] has at least one inlet opening for the introduction of at
least one feed stream into a linking channel lying in the plane of
the disk and at least one outlet opening for the outflow of the
feed stream into a mixing zone lying in the plane of the disk,
[0009] wherein the inlet opening is connected with the outlet
opening in a communicating manner through a linking channel lying
in the plane of the disk and
[0010] wherein the linking channel before opening into the mixing
zone is divided by microstructure units into two or more part
channels, the widths of the part channels being in the millimeter
to submillimeter range and being smaller than the width of the
mixing zone.
[0011] The term "part channels" also includes division of the feed
stream into part streams by built-in microstructure parts just
before the outflow of said feed stream into the mixing zone. The
dimensions, particularly the lengths and widths of these built-in
parts, can be in the range of millimeters or preferably smaller
than 1 mm. The part channels are preferably shortened to the length
that is absolutely needed for flow control and, hence, for a
certain throughput they require comparatively low pressures. The
length-to-width ratio of the part channels is preferably in the
range from 1:1 to 20:1, particularly from 8:1 to 12:1and most
preferably about 10:1. The built-in microstructure parts are
preferably configured in such a way that the flow rate of the feed
stream at the outlet into the mixing zone is greater than at the
inlet into the linking channel and preferably also greater than the
flow rate of the product stream through the mixing zone.
[0012] The linking channel and part channels disposed on the disks
can be provided in free form. Both the disks and each channel
disposed thereon can vary in height, width and thickness so as to
also be able to convey different media and different quantities.
The basic shape of the disks can be of any desired kind, for
example it can be round or circular or else elliptical or angular,
for example rectangular or square. The disk shape can also be
optimized in terms of simple fabrication or in terms of minimum
weight or minimum unused surface. The outlets of the part channels
can be arranged in any desired manner from a straight line to any
geometric form. For example, the outlet openings can be arranged on
a circular line, particularly when the mixing zone is completely
enclosed by the plane of the disk. Two or more than two components
(A, B, C etc) can be conveyed in a disk and mixed in identical or
different quantity ratios. The part channels can be disposed at any
angle to each other or relative to the line on which the outlets
into the mixing zone are disposed. Several part channels, each
conveying, for example, component A, can be arranged side by side,
and in the adjacent section of the same disk there can be arranged
side by side several part channels conveying, for example,
component B. However, the components can, by means of additional
through-holes and additional part channels in the disks, be
configured so that components A, B etc alternate from part channel
to part channel in the same disk.
[0013] At their entrance to the mixing zone, the part channels
preferably have a width in the range from 1 .mu.m to 2 mm and a
depth in the range from 10 .mu.m to 10 mm and most preferably a
width in the range from 5 .mu.m to 250 .mu.m and a depth in the
range from 250 .mu.m to 5 mm.
[0014] The linking channel can have a variable width. Preferably,
the ratio of the greatest width of the linking channel and/or the
width of the inlet opening to the width of the part channels at
their outlet into the mixing zone is greater than 2 and most
preferably greater than 5. The ratio of the width of the mixing
zone to the width of the part channels is preferably greater than 2
and most preferably greater than 5.
[0015] The disk-shaped components can be from 10 to 1000 .mu.m
thick. The height of the channels is preferably less than 1000
.mu.m and most preferably less than 250 .mu.m. The wall thickness
of the built-in microstructure components and of the channel bottom
is preferably less than 100 .mu.m and most preferably less than 70
.mu.m.
[0016] In a particular embodiment, at least one of the inlet or
outlet openings or the mixing zone is completely enclosed by the
plane of the disk. In this case, the openings are in the form of,
for example, round or angular, for example rectangular, recesses.
In the case of an enclosed mixing zone, the elliptical or circular
shape is preferred. The part channel can taper off in the form of
nozzles in the direction of the mixing zone. The part channels can
be linear or bent in the shape of a spiral. The part channels can
enter into the mixing zone at a right angle relative to the
circumferential line of the mixing zone or at an angle different
from 90.degree.0. When in the event that the angle is different
from a right angle a stack of several mixer disks is formed,
preferably the disks with opposite deviation from a right angle are
adjacent to each other. Similarly, when a stack of several mixer
disks is formed, then, in the event that the course of the part
channels is spiral-shaped, disks with oppositely oriented direction
of spiral rotation are preferably adjacent to each other.
[0017] The linking channel between the openings is preferably
formed by an indentation. The inlet opening and/or outlet opening
or the mixing zone, however, can also be disposed at the edge of
the disk or be in the form of recesses at the edge of the disk.
[0018] In another particular embodiment, there are present at least
two inlet openings for at least two different feed streams, each
inlet opening being connected with the mixing zone through a
linking channel. In this case, there are preferably two outlet
openings for two different feed streams on opposite sides of the
mixing zone, the mixing zone preferably being in a position
completely enclosed within the disk plane.
[0019] Suitable materials of construction for the components are,
for example, metals, particularly corrosion-resistant metals, such
as, for example, stainless steel, as well as glasses, ceramic
materials or plastic materials. The components can be fabricated by
techniques for producing microstructures on surfaces, techniques
that in and of themselves are known, for example by etching or
milling of metals or by embossing or injection-molding of
plastics.
[0020] The static micromixer of the invention has a housing with at
least 2 inlets for fluids and at least one outlet for fluids. In
the housing are located at least two disk-shaped micromixer
components of the invention, arranged in a stack. Stacks can be
formed from any number of disks, permitting a through-flow
commensurate with the height of the stack. To ensure the same
pressure throughout the mixer, in the case of greater lengths the
fluid can be introduced at several points. Grooves or ribs can be
used for purposes of stacking and aligning. The disks are
superposed on one another so that the inlet openings form
subsidiary channels for introducing a particular feed stream and
the outlet openings or the mixing zone together form a main channel
for removing the product stream, the main channels and subsidiary
channels extending through the stack. Overall, a micromixer can
have, for example, at least 5, 10, 100 or even more than 1000 part
channels and it consists of a stack of disks having several part
channels.
[0021] Preferably, each part stream of a first feed A flowing from
an outlet opening of a disk into the mixing zone is directly
adjacent to a part stream of a second feed B flowing from an outlet
opening of an adjacent disk into the mixing zone. In the mixing
zone, the mixing takes place by diffusion and/or turbulence.
[0022] In another embodiment of the micromixer, the linking
channels of the disks are formed by indentations. Before they end
in the mixing zone, the linking channels are divided into part
channels by microstructure units disposed on the disks. In an
alternative embodiment, the linking channels of the disks are
formed as recesses in the disks, the disks being arranged as
intermediate disks between a cover disk and a bottom disk, and the
linking channels, before they end in the mixing zone are divided
into part channels by microstructure units disposed on the cover
disk and/or bottom disk. Heat-supplying or heat-removing heat
exchangers can be integrated into the micromixers of the
invention.
[0023] Above all, the micromixer of the invention is also suited
for chemical reactions of gaseous components, particularly for
combustion reactions. An object of the invention therefore is a
combustion reactor, for example a gas burner or an oil burner. The
combustion reactor contains a micromixer of the invention as an
essential constituent as well as at least a first connection for
supplying a combustible liquid or gaseous medium and at least one
second connection for supplying an oxygen-containing medium
promoting the combustion reaction, for example air. The supply of
these components can be arranged so that certain quantities
characterizing the reaction are optimized. This is true, in
particular, for the flame temperature and the products formed by
the reaction. In the case of combustion of a burnable gas (for
example methane) with atmospheric air, the formation of nitrogen
oxides can be minimized by reducing the combustion temperature. The
flame can be made concentrated or divergent by an appropriate
convex or concave configuration of the outlet openings. By an
appropriate arrangement of the channels, it is also possible to
achieve locally limited auxiliary flames supplied from one of the
subsidiary channels with gas at constant pressure. By connecting
the other subsidiary channels, the reaction can then be started.
Cylinder-shaped reaction chambers (mixing zones) for creating
nozzle-like burners are also possible. Besides media of the same
kind such as gas/gas, different kinds of media such as gas/liquid
can also be mixed, particularly to burn combustible liquids, for
example gasoline or oil.
[0024] An object of the invention is also a process for mixing
fluid components, whereby at least two fluid feed streams that at
first are kept separated can be mixed with one another, the mixing
being carried out by use of at least one component of the invention
or of a static micromixer of the invention. To this end, the flow
rate of the feed stream or feed streams in the mixing zone is
preferably greater than the flow rate of the product mixture within
the mixing zone. Particularly preferred are mixer configurations
and flow rates at which turbulence is created in the mixing zone
and the mixing in the mixing zone takes place at least partly as a
result of turbulence.
[0025] The mixing process of the invention comprises in particular
also homogenization processes, processes for the production of
dispersions, emulsions or solutions as well as for the gassing of
liquids. To this end, a continuous liquid phase is mixed with at
least one insoluble fluid phase that is to be dispersed or with at
least one soluble fluid phase by use of at least one component of
the invention or of a static micromixer of the invention. The two
phases can either be introduced through various subsidiary channels
or one phase (preferably the continuous phase) is introduced
through the main channel and the second phase through a subsidiary
channel.
[0026] Another object of the invention is a process for carrying
out chemical reactions whereby
[0027] at least two fluid feed streams which at first are kept
separated and which contain or consist of reactive components are
mixed with one another and whereby
[0028] during or after the mixing a chemical reaction between the
components takes place spontaneously or is induced by supplying
energy or by a suitable catalyst and whereby
[0029] the mixing is carried out by use of at least one component
of the invention or at least one static micromixer of the
invention.
[0030] To increase the capacity of the process of the invention,
the number of channels in the disks can be increased or the number
of the disks superposed on one another in a micromixer can be
increased or several micromixers can be connected together in
parallel and operated as a module. It is also possible to operate
two or more micromixers connected in series. It is particularly
advantageous if in this case a coarse premix is first made with a
micromixer having larger channel diameters and then with
micromixers with increasingly smaller channel diameters.
[0031] In the following, exemplary embodiments of the components
and micromixers of the invention are explained by reference to the
drawings.
[0032] FIG. 1a-b shows mixing disks with two inlet openings for two
feed streams and wherein the inlet opening and outlet opening are
enclosed,
[0033] FIG. 1c shows a mixing disk with a single inlet opening and
wherein the inlet opening and outlet opening are enclosed,
[0034] FIG. 1d shows a mixing disk with enclosed inlet opening,
through-flow opening and outlet opening,
[0035] FIG. 2a-c shows mixing disks with three inlet openings for
up to three different feed streams and wherein the inlet opening
and outlet opening are enclosed,
[0036] FIG. 3a-b shows mixing disks with two inlet openings at the
edge of the disk for two feed streams and with an enclosed outlet
opening,
[0037] FIG. 3c-d shows mixing disks with four inlet openings at the
edge of the disk for up to four different feed streams and with an
enclosed outlet opening,
[0038] FIG. 4a-f shows mixing disks each with an enclosed inlet
opening and flow-through opening for two feed streams and an outlet
opening at the edge of the disk,
[0039] FIG. 5a-b shows mixing disks each with one enclosed inlet
opening and two enclosed through-flow openings for up to three
different feed streams and an outlet opening at the edge of the
disk,
[0040] FIG. 6a shows a longitudinal section of the schematic
structure of a static micromixer that can be used as a
microreactor,
[0041] FIG. 6b shows a mixing disk in an open housing,
[0042] FIG. 7a-b shows mixing disks with enclosed inlet opening and
through-flow opening and additional part channels, wherein
different feed streams can flow through adjacent part channels,
[0043] FIG. 8a,c shows mixing disks with enclosed inlet and
flow-through openings and additional part channels, wherein
different feed streams can flow through adjacent part channels,
[0044] FIG. 8b shows a mixing disk with enclosed inlet opening,
three enclosed flow-through openings and additional part channels,
wherein different feed streams can flow through adjacent part
channels, and
[0045] FIG. 9 shows a micromixer with a housing and a stack of
several mixing disks.
[0046] One embodiment is shown in FIG. 1a and FIG. 1b. The disks
(1) have two enclosed inlet openings (2). Each inlet opening (2) is
connected with one linking channel (3) formed by an indentation in
the plane of the disk. By a multiplicity of microstructure units
(6), each linking channel (3) is divided into a multiplicity of
part channels (7). Through the outlet openings (4), the part
channels (7) open into an enclosed mixing zone (5). The outlet
openings (4) are arranged on a circular line around the mixing zone
(5). The mixing zone (5) and the inlet openings (2) are formed as
through-holes in the disks. The microstructure units are bent, for
example, in the form of spirals, the spirals in FIG. 1a and FIG. 1b
having an opposite sense of rotation. The microstructure units,
however, can also be linear or unbent. When the disks are round,
they preferably have recesses (8) at the edge which can cooperate
with fixing elements (14) in a housing (11) to prevent torsion or
slipping. The disks, however, can also be angular, preferably
quadrangular, for example in the shape of a square. In this case,
the recesses and fixing elements may be omitted. Through the two
inlet openings (2) two different feed streams can be introduced
into the mixing zone (5) in one plane, the two outlet openings
corresponding to the two different feed streams preferably being
disposed opposite each other. A micromixer preferably has a stack
of several components superposed on one another, with disks of the
kind shown in FIG. 1a alternating with disks of the kind shown in
FIG. 1b and giving rise to an arrangement consisting of an
alternating layer structure ABAB etc. In this manner, two different
feed streams can be fed to the mixing zone (5) directly adjacent
and over and under one another. In the stack, the disks are
superposed on one another in such a way that the inlet openings
form subsidiary channels for introducing a particular feed stream,
and the mixing zones form a main channel for removing the product
stream. A fluid which later will constitute the continuous phase of
the mixture, however, can also be introduced through the main
channel.
[0047] Another embodiment is shown in FIG. 1c. The disk (1) has a
single enclosed inlet opening (2) which is connected with a linking
channel (3) formed by an indentation in the disk plane. The linking
channel (3) is divided by a multiplicity of microstructure units
(6) into a multiplicity of part channels (7). The part channels (7)
open through the outlet openings (4) into the mixing zone (5). The
outlet openings (4) are arranged on a circular line around the
mixing zone (5). The mixing zone (5) and the inlet opening (2) are
configured as through-holes in the disk. The microstructure units
are bent, for example, in the shape of a spiral. The microstructure
units, however, can also be linear, unbent or have any other
geometric shape. A micromixer preferably has a stack of several
components superposed on one another. In the stack, the disks are
disposed above one another in a manner such that the inlet openings
form a subsidiary channel for introducing a feed stream, and the
mixing zones form a main channel for removing the product stream.
Through the main channel can be introduced one of the components to
be mixed, preferably the fluid which later will form the continuous
phase of the mixture. This embodiment is particularly well suited,
for example, for gassing liquids or for preparing dispersions. To
this end, the liquid to be treated with the gas or the dispersing
medium is introduced through the central main channel and the gas
or the substance to be dispersed is introduced through the
subsidiary channel. Advantageously, the stack of disks can be
configured as an alternating layer structure wherein disks with
spiral-shaped microstructure units (6) of opposite sense of
rotation are alternately disposed one above the other. It is also
possible to use only a single type of disk. The microstructure
units are then preferably linear and shaped so that the part
channels form nozzles.
[0048] Another embodiment is shown in FIG. 1d. The disk (1) has an
enclosed inlet opening (2), an enclosed mixing zone (5) and an
enclosed flow-through opening (9). The inlet opening (2) is
connected with a linking channel (3) formed by an indentation in
the disk plane, which channel by a multiplicity of microstructure
units (6) is divided into a multiplicity of part channels (7). The
part channels (7) open through the outlet openings (4) into the
mixing zone (5). The outlet openings (4) are arranged on a circular
line around the mixing zone (5). The mixing zone (5), inlet opening
(2) and flow-through opening (9) are configured as through-holes in
the disk. The microstructure units are, for example, bent in the
form of spirals. The microstructures units, however, can also be
linear, unbent or have any other geometric shape. With additional
built-in components (10) in the linking channel, the flow
conditions in the linking channel (3) can be optimized. When the
disks are round, they preferably have at their edges recesses (8)
that can cooperate with fixing elements 14) in a housing (11) to
prevent twisting or slipping of the disks. A micromixer preferably
has a stack of several disks of the kind shown in FIG. 1d and
disposed above one another alternately twisted by 180.degree.. In
this manner, two different feed streams can be introduced into the
mixing zone (5) directly adjacent and above and under one another.
In the stack, the disks are superposed on one another in a manner
such that the inlet openings (2) and the flow-through openings (9)
alternate and form two subsidiary channels for introducing two feed
streams, the mixing zones forming a main channel for removing the
product stream. A fluid which later will constitute the continuous
phase of the mixture, however, can also be introduced through the
main channel. Advantageously, the stack of disks can have a
configuration with an alternating layer structure wherein disks
with spiral-shaped microstructure units (6) of opposite sense of
rotation are disposed alternately one above the other. A single
type of disk, however, can also be used. The microstructure units
are preferably linear and configured in such a way that the part
channels form nozzles.
[0049] FIGS. 2a to 2c show another embodiment. Each of the disks
(1) has three enclosed inlet openings (2). Each inlet opening (2)
is connected with a linking channel (3) formed by an indentation in
the plane of the disk. Each linking channel (3) is divided by at
least one microstructure unit (6) into at least two part channels
(7). By means of a larger number of microstructure units, division
into a higher number of part channels can be achieved. Through the
outlet openings (4), the part channels (7) open into the mixing
zone (5). The outlet openings (4) are arranged on a circular line
around the mixing zone (5). The mixing zone (5) and the inlet
openings (2) are configured as through-holes in the disks. The
microstructure units can be in the form of spirals having a
different sense of rotation or they can be linear. Through the
three inlet openings (2), equal feed streams or up to three
different feed streams can be introduced into the mixing zone (5)
in one plane. A micromixer preferably has a stack of several
components disposed one above another wherein different types of
disks as shown in FIGS. 2a, 2b and 2c alternate forming an
alternating layer structure, for example ABCABC. In this manner,
two different feed streams can be introduced into the mixing zone
(5) directly adjacent and over and under one another. In the stack,
the disks are disposed above one another so that the inlet openings
form subsidiary channels for introducing a particular feed stream,
and the mixing zones form a main channel for removing the product
stream. A fluid which later will constitute the continuous phase of
the mixture, however, can also be introduced through the main
channel.
[0050] Another embodiment is shown in FIG. 3a and FIG. 3b. The
disks (1) have two inlet openings positioned at the edge of the
disk. Each inlet opening (2) is connected with a linking channel
(3) formed by an indentation in the plane of the disk. Each linking
channel (3) is divided by a multiplicity of microstructure units
(6) into a multiplicity of part channels (7). Through the outlet
openings (4), the part channels (7) open into an enclosed mixing
zone (5). The outlet openings (4) are arranged on a circular line.
The mixing zone (5) is configured, for example, as a rectangular
through-hole in the disks. The microstructure units are disposed,
for example, at a slant to the direction of flow, the inclinations
in FIGS. 1 and 1b extending in opposite directions. The
microstructure units, however, can also have the same inclination
or no inclination at all. The disks have an approximately
quadrangular basic shape, but they can also have any other basic
geometric shape (angular, round, elliptical etc). Through the two
inlet openings (2), two different feed streams can be introduced
into the mixing zone (5) in one plane, with the two outlet openings
for the two different feed streams preferably disposed opposite
each other. A micromixer preferably has a stack of several
components disposed above one another wherein disks of the kind
shown in FIG. 3a alternate with disks of the kind shown in FIG. 3b
forming an alternating layer structure ABAB. In this manner, two
different feed streams can be introduced into the mixing zone (5)
directly adjacent and over and under one another. In the stack, the
disks are disposed above one another so that the inlet openings
together with the mixer housing form at the edge of the mixer
subsidiary channels for introducing a particular feed stream, and
inside the mixer the mixing zones form a main channel for removing
the product stream. A fluid later constituting the continuous phase
of the mixture, however, can also be introduced through the main
channel.
[0051] Another embodiment is shown in FIG. 3c and FIG. 3d. Each
disk (1) has four inlet openings (2) positioned at the edge of the
disk. Each inlet opening (2) is connected with a linking channel
(3) formed by an indentation in the plane of the disk. Each linking
channel (3) is divided by several microstructure units (6) into
several part channels (7). Through the outlet openings (4), the
part channels (7) open into an enclosed mixing zone (5). The outlet
openings (4) are arranged on a circular line. The linking channels
are bent into spiral shapes, the spirals in FIGS. 3c and 3d having
an opposite sense of rotation. The mixing zone (5) is configured as
a through-hole in the disks. The microstructure units are, for
example, straight, but they can also be bent at an angle or bent
like a spiral. The disks have an approximately square basic shape,
but they can also have any other basic geometric shape (angular,
round, elliptical etc). Through the four inlet openings (2), equal
feed streams or up to four different feed streams can be introduced
into the mixing zone (5) in one plane, with the outlet openings for
the different feed streams preferably disposed opposite one
another. A micromixer preferably has a stack of several components
disposed above one another wherein disks of the kind shown in FIG.
3c alternate with disks of the kind shown in FIG. 3d and having a
sense of rotation opposite to that of spiral-shaped linking
channels, thus forming an alternating layer structure ABAB. In this
manner, two different feed streams can be introduced into the
mixing zone (5) directly adjacent and over and under one another.
In the stack, the disks are disposed above one another so that the
inlet openings together with the mixer housing form at the edge of
the mixer subsidiary channels for introducing a particular feed
stream, and inside the mixer the mixing zones form a main channel
for removing the product stream. A fluid which later will
constitute the continuous phase of the mixture, however, can also
be introduced through the main channel.
[0052] Additional embodiments are shown in FIG. 4a to FIG. 4f. Each
disk (1) has an enclosed inlet opening (2) and an enclosed
flow-through opening (9). Each inlet opening (2) is connected with
a linking channel (3) formed by an indentation in the plane of the
disk. By a multiplicity of microstructure units (6), each linking
channel (3) is divided into a multiplicity of part channels (7).
Through outlet openings (4) arranged at the edge of the disks, the
part channels (7) open into the mixing zone (5) disposed outside
the plane of the disk. The outlet openings (4) can be arranged on
straight lines (FIGS. 4e, 4f) or on arc segments, the arc segments
being convex (FIGS. 4a, 4b) or concave (FIGS. 4c, 4d). The inlet
openings (2) and the flow-through openings (9) are configured as
through-holes in the disks. The microstructure units can be
parallel or they can be arranged at various angles to the flow
direction preset by the linking channel. When the disks are round,
they preferably have at their edge recesses (8) which can cooperate
with fixing elements (14) in a housing (11) to prevent twisting or
slipping of the disks. A micromixer preferably has a stack of
several components disposed above one another, the disks of the
kind shown in FIG. 4a alternating with disks of the kind shown in
FIG. 4b, or disks of the kind shown in FIG. 4c alternating with
disks of the kind shown in FIG. 4d, or disks of the kind shown in
FIG. 4e alternating with disks of the kind shown in FIG. 4f, giving
rise to an alternating layer structure ABAB. In this manner, two
different feed streams can be fed to the mixing zone (5) directly
adjacent and over and under one another. Preferably, the angles at
which the part channels open into the mixing zone are different
relative to the circumferential line of the mixing zone in adjacent
disks and preferably have opposite deviations of 90.degree.. In the
stack, the disks are disposed over one another in a manner such
that the inlet openings (2) and the flow-through openings (9)
alternate and inside the mixer form two subsidiary channels for
introducing two feed streams. The mixing zone and a housing can
form a main channel for removing the product stream, the mixing
zone also possibly being open to the surroundings. The outwardly
open configuration is particularly preferred if the micromixer is a
microreactor for burning fluid media, for example combustible gases
or liquids. An embodiment configured as a gas reactor has at least
one first connection for supplying a combustible medium and at
least one second connection for supplying a burning
reaction-promoting medium, particularly an oxygen-containing gas,
for example air. The burnable medium and the medium promoting the
burning can each be supplied through one of the two subsidiary
channels.
[0053] Other embodiments are shown in FIG. 5a and FIG. 5b. Each of
the disks (1) has an enclosed inlet opening (2) and two enclosed
flow-through openings (9). Each inlet opening (2) is connected with
a linking channel (3) formed by an indentation in the plane of the
disk. By a multiplicity of microstructure units (6), each linking
channel (3) is divided into a multiplicity of part channels (7).
Through outlet openings (4) arranged at the edge of the disks, the
part channels (7) open into the mixing zone (5) disposed outside
the plane of the disk. The outlet openings (4) can be arranged on
straight lines (FIG. 5a) or on arc segments (FIG. 5b), the arc
segments being convex or concave. The inlet openings (2) and the
flow-through openings (9) are configured as through-holes in the
disks. The microstructure units can be parallel or they can be
arranged at various angles to the flow direction preset by the
linking channel. When the disks are round, they preferably have at
their edge recesses (8) which can cooperate with fixing elements
(14) in a housing (11) to prevent twisting or slipping of the
disks. A micromixer preferably has a stack of several components
disposed above one another, the disks of the three different kinds
shown in FIG. 5a alternating with those of the kind shown in FIG.
5b giving rise to an alternating layer structure ABCABC. In this
manner, two different feed streams can be fed to the mixing zone
(5) directly adjacent and over and under one another. Preferably,
the angles at which the part channels open into the mixing zone
differ relative to the circumferential line of the mixing zone in
adjacent disks, opposite deviations of 90.degree. being
particularly preferred. In the stack, the disks (1) are disposed
over one another in a manner such that the inlet openings (2) and
the flow-through openings (9) alternate and inside the mixer form
three subsidiary channels for introducing up to three different
feed streams. The mixing zone (5) and a housing can form a main
channel for removing the product stream, the mixing zone also
possibly being open to the surroundings. The outwardly open
configuration is particularly preferred when the micromixer is a
microreactor for burning fluid media, for example burnable gases or
liquids.
[0054] FIG. 6a shows the schematic structure of an embodiment of a
static micromixer in longitudinal section. A housing (11) is
provided with fluid inlets (12a). The housing (11) contains a stack
of several mixer disks (1) of the invention. The inlet openings
and/or flow-through openings of the disks can be closed and opened
by means of a closure (13a) which is preferably displaceable
perpendicularly to the plane of the disk. The micromixer can be
used as a reactor for carrying out chemical reactions, particularly
as a gas burner.
[0055] In the case of combustion reactors, the mixing zone in which
the combustion reaction takes place can be located outside the
housing. In the case of other chemical reactors and mixers, the
mixing zone can be located within the housing, and the mixture can
be removed through an appropriate fluid outlet. In combustion
reactors, a suitable ignition mechanism and/or a starting or
auxiliary flame is preferably provided in spatial vicinity of the
mixing zone.
[0056] FIG. 6b shows the cross-section of a static mixer. Into a
housing (11) is built a mixer disk (1) held in position by means of
recesses (8) and fixing elements (14). The mixer disk is, for
example, of the kind shown in FIG. 5a.
[0057] Other, preferred embodiments are shown in FIGS. 7a-b and
FIGS. 8a-c. In these embodiments, the disks (1) have adjacent part
channels (7) and (13) through which different feed streams can flow
alternately so that different feed streams can be introduced into
the mixing zone (5) directly adjacent in one plane.
[0058] Each of the disks (1) shown in FIG. 7a has an enclosed inlet
opening (2), an enclosed mixing zone (5) and an enclosed
flow-through opening (9). The inlet opening (2) is connected with a
linking channel (3) formed by an indentation in the plane of the
disk, said linking channel being divided into a multiplicity of
part channels (7) by a multiplicity of microstructure units (6).
Through the outlet openings (4), the part channels (7) open into
the mixing zone (5). The outlet openings (4) are arranged on a
circular line around the mixing zone (5). The mixing zone (5), the
inlet opening (2) and the flow-through opening (9) are configured
as through-holes in the disk. Into the microstructure units (6) are
integrated other part channels (13) configured as indentations and
which are shielded against the linking channel (3) and open into
the mixing zone (5). The part channels (7) and the other part
channels (13) are alternately disposed adjacent to each other. The
disks are provided with additional through-holes (12), the number
of the through-holes (12) and the number of the additional part
channels (13) being identical. The through-holes (12) are arranged
so that when a disk (1) is placed on a second disk (1) twisted by
180.degree. they are disposed above the additional part channels
(13) of the disk that is positioned underneath. A feed stream
flowing through the inlet opening (2) into the linking channel (3)
can flow through the through-holes (12) into an additional part
channel (13) of a disk positioned underneath. The angle formed
between the adjacent part channels (7) and (13) and the angle
relative to the circumferential line of the mixing zone can be
different. In FIG. 7a, the angles of the part channels (7) and of
the additional part channels (13) relative to the circumferential
line of the mixing zone (5) have opposite deviations of 90.degree..
As a result, the outlet openings of each two part channels form a
pair. In this manner, two different feed streams can be introduced
on top of each other. The part channels, however, can also run
parallel, at right angles or inclined toward the mixing zone. FIG.
7a shows next to each other two identical disks (1) twisted by
180.degree.. FIG. 7b shows schematically two superposed disks
twisted by 180.degree.. A micromixer preferably has a stack of
several superposed components wherein disks of the kind shown in
FIG. 7a twisted by 180.degree. are alternately superposed on one
another. In this manner, two different feed streams can be fed to
the mixing zone (5) both directly adjacent and over and under one
another and also directly adjacent and next to each other. In the
stack, the disks are disposed above one another so that the inlet
openings (2) and the flow-through openings (9) alternate and form
two subsidiary channels for introducing two feed streams, and the
mixing zones form a main channel for removing the product stream. A
fluid which later will constitute the continuous phase of the
mixture, however, can also be introduced through the main channel.
Moreover, the disks are disposed above one another so that each
additional through-hole (12) of a disk is connected in
communicating manner with one corresponding additional part channel
(13) of an adjacent disk.
[0059] FIG. 8a shows an embodiment similar to that of FIG. 7a the
difference being that the part channels (7) and the additional part
channels (13) lead to the mixing zone (5) in parallel and inclined
at identical angles. The disk on the left in FIG. 8a differs from
the disk on the right in that the angle formed between the part
channels (7) and (13) and the circumferential line of the mixing
zone (5) has an opposite deviation of 90.degree.. A micromixer
preferably has a stack of several superposed components wherein the
left and the right disks shown in FIG. 8a alternate giving rise to
an alternating layer structure ABAB. In this manner, two different
feed streams can be introduced into the mixing zone (5) directly
adjacent and over and under each other at opposite angles.
[0060] FIG. 8c shows an embodiment similar to that of FIG. 8a the
difference being that the part channels (7) and the additional part
channels (13) lead to the mixing zone (5) in parallel and
vertically. A micromixer preferably has a stack of several
superposed components wherein the left and right disks of the kind
shown in FIG. 8c alternate resulting in an alternating layer
structure ABAB. In the stack, the disks are superposed on one
another so that the inlet openings (2) and the flow-through
openings (9) alternate and form two subsidiary channels for
introducing two feed streams and the mixing zones form a main
channel for removing the product stream. Moreover, the disks are
superposed on one another so that each additional through-hole (12)
of a disk is connected in communicating manner with a corresponding
additional part channel (13) of an adjacent disk. In this manner,
two different feed streams can be introduced into the mixing zone
(5) both directly adjacent and over and under each other and
directly adjacent and next to each other.
[0061] Another embodiment is shown in FIG. 8b. A disk (1) has an
enclosed inlet opening (2), three enclosed flow-through openings
(9) and one enclosed mixing zone (5). The inlet opening (2) is
connected with a linking channel (3) formed by an indentation in
the plane of the disk and which by a multiplicity of microstructure
units (6) is divided into a multiplicity of part channels (7).
Through the outlet openings (4), the part channels (7) open into
the mixing zone (5). The outlet openings (4) are arranged on a
circular line around the mixing zone (5). The mixing zone (5), the
inlet opening (2) and the flow-through opening (9) are configured
as through-holes in the disk. Into the microstructure units (6) are
integrated in indented manner additional part channels (13) which
are shielded against the linking channel (3) and which open into
the mixing zone (5). The part channels (7) and the additional part
channels (13) are disposed alternately adjacent to each other. The
disks have additional through-holes (12), the number of the
through-holes (12) and the number of the additional part channels
(13) being identical. The through-holes (12) are arranged so that
when a disk (1) twisted by 90.degree. is placed on a second disk
(1) they are positioned above the additional part channels (13) of
the disk located underneath. A feed stream flowing through the
inlet opening (2) into the linking channel (3) can flow through the
through-holes (2) into the additional part channel (13) of a disk
positioned below. The angle formed by the adjacent part channels
(7) and (13) and the angle relative to the circumferential line of
the mixing zone can be different. In FIG. 8b the angles of the part
channels (7) compared to the angles of the additional part channels
(13) have an opposed deviation of 90.degree. relative to the
circumferential line of the mixing zone (5). As a result, the
outlet openings of each two part channels form a pair. In this
manner, two different feed streams can be introduced on top of each
other. The part channels, however, can also run parallel at a right
angle or inclined toward the mixing zone. A micromixer preferably
has a stack of several superposed components, the disks being
disposed above one another with disks of the kind shown in FIG. 8b
being disposed above one another in any order and each being
twisted by 90.degree., 180.degree. or 270.degree.. In this manner,
different feed streams can be introduced into the mixing zone (5)
either directly adjacent and over and under one another or directly
adjacent and next to each other. Overall, up to four different feed
streams can be mixed by means of the micromixer. In the stack, the
disks are superposed on one another so that the inlet openings (2)
and the flow-through openings (9) alternate and form a total of
four subsidiary channels for introducing up to four feed streams
and the mixing zones form a main channel for removing the product
stream. A fluid which later will constitute the continuous phase of
the mixture, however, can also be introduced through the main
channel. Moreover, the disks are superposed on one another so that
each additional through-hole (12) of a disk is connected in
communicating manner with the corresponding additional part channel
(13) of an adjacent disk.
[0062] In FIG. 9 is shown as an example a possible embodiment of a
micromixer of the invention in an exploded view. A housing (11)
contains a stack of components of the invention in the form of
disks (1). Shown as an example is a stack of several disks of the
kind shown in FIG. 8a, but other disks of the invention can also be
used, in which case optionally the shape of the housing, the number
and position of the inlets and outlets of the fluid etc must be
correspondingly adapted. The disks (1) are positioned so that the
recesses (8) cooperate with the fixing elements (14) so as to
prevent the twisting of the disks. The housing has two fluid inlets
(12a) for introducing the feed streams. The housing can be closed
with a cover (15) containing the fluid outlet (16).
LIST OF REFERENCE NUMERALS
[0063] 1 disk [0064] 2 inlet opening [0065] 3 linking channel
[0066] 4 outlet opening [0067] 5 mixing zone [0068] 6
microstructure unit [0069] 7 part channel [0070] 8 recess [0071] 9
flow-through opening [0072] 10 built-in components [0073] 11
housing [0074] 12 through-hole [0075] 12a fluid inlet [0076] 13
additional part channel [0077] 13a closure [0078] 14 fixing element
[0079] 15 cover [0080] 16 fluid outlet
* * * * *